AerospaceMADE BY MAGNA
Parts used in the propulsion system of a space launch vehicle have to withstand the most severe operating conditions. Highest quality standards in design and manufacturing are therefore paramount in order to guarantee a successful mission. Magna’s experience in cryogenic propellant lines goes back to the 1990s. As a development and manufacturing partner for the Ariane 5 program Magna was actively involved in one of the most successful launch vehicle programs in history.
Our experience ranges from small high-pressure helium lines to large-diameter feed lines for liquid hydrogen (LH2) and liquid oxygen (LOX) made from stainless steel, nickel-based alloys, aluminum and titanium. Our state-of-the-art welding and non-destructive inspection (NDI) processes, combined with highly trained and experienced personnel, vouch for absolute world class manufacturing.
We also operate clean rooms, precision cleaning facilities and labs as well as facilities for molding of foam insulation parts for our propellant lines.
One of our most remarkable developments is an Aluminum Compensator (Gimbal and Angular Axial Compensator). With the support of ESA’s Future Launchers Preparatory Program, Magna developed, built and tested a compensator comprising an aluminum structure and a stainless steel bellows to TRL level. This new technology, together with aluminum propellant lines, promises mass savings of 30% compared to conventional propellant feed lines.
Magna supplies the aeronautics industry with metallic piping and ducting systems. Our extensive experience in the manufacture of welded fluid conveyance components is trusted by reputed aerospace companies. This type of equipment requires extensive knowledge of the manufacturing processes and efficient project execution.
Our capability encompasses all kinds of metallic pipes and ducts, from bleed air to fuel and hydraulics. Magna gained multiple customer approvals for manufacturing and special processes and applied for NADCAP? certification in 2019. Since 2015, Magna Aerospace is certified under EASA Part21 G (Production Organization approval) and authorized to ship parts with EASA Form 1.
Alternative fuel systems, for example with compressed natural gas (CNG) or hydrogen (H2), operate under high pressures from 260 bar (3,770 psi) up to 700 bar (10,150 psi). The safe handling of such highly pressurized gases requires a high quality level in production and advanced cleaning processes to ensure the proper function of other components such as valves and regulators.
These demanding requirements are our everyday business in aerospace, and this allows us to leverage significant synergies for the benefit of our automotive customers. Our processes include CNC bending, welding, fitting, assembly, cleaning as well as pressure and leakage testing.
Magna is the leading company for developing and manufacturing liquid hydrogen (LH2) tanks for mobile applications, and it was the first company to build an automotive liquid hydrogen tank in small series production. This unique expertise was also transferred into R&D programs for liquid hydrogen systems in aircraft, and it may be one of the key enablers of future mobility solutions. The current competences range from development and prototyping to small-scale series production.
We are also working on propellant tanks (Composite Overwrapped Pressure Vessels - COPVs) for satellites. It is our goal to transfer the automotive pressure vessel technology into the space market in order to provide the best cost-to-performance ratio for future spacecraft.
Magna Steyr Aerospace has established a very solid management system that conforms to the following standards/regulations:
- EN 9100 Quality management systems for aerospace
- ISO 3834-2 Quality requirements for welding
- EASA Part 21 G Production organization approval
- ISO 14001 Environmental management system
- OHSAS 18001 Operational safety management system
- ISO/IEC 27001 Data security management system
Additionally, we hold several active customer approvals for manufacturing and special processes e.g. from Ariane Group, Boeing (D1-4426 Approved Processor) and MTU Aero Engines.
As a means of continuous improvement, Magna applied for certification according to the NADCAP? requirements for fusion welding, fluorescent penetrant inspection in 2019, and it is our aim to be certified for radiographic inspection by 2020.